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‘For the average conversion, where the owneris after more power and better mpg, the EJ20

naturally-aspirated engine from a 1995-onLegacy or Impreza is often a better choice’

at least 12 years old now, and tend to have done a lot of miles. For theaverage conversion, where the owner is after more power and bettermpg, the EJ20 naturally-aspirated engine from a 1995-on Legacy orImpreza is often a better choice. Our choice, though, was a 2.5-litre EJ25Legacy engine, which pumps out a healthy 155bhp.

One thing to be aware of is that, while grey-import Subaru enginesare common – especially turbos – and are more powerful than their UKequivalents, dealers often cannot provide any support or parts for them.

But what about fuel economy? A converted T25 will happily cruisemuch faster than 65mph, but economy drops off rapidly due to itsaerodynamics. As an example, the RJES T25 Syncro (with a 160bhpEJ25 import engine with VVT) gets 23–27 mpg; typically, a 2WD T25 witha 130bhp EJ22 engine will return 24–30 mpg.

Suitable VW transaxlesThe RJES Subaru conversion bell-housing kits fit all rear-engined manualVW Bus transaxles from 1968–1992. There are two kits: one to suit theclutch from a naturally-aspirated Subaru (it’s a conventional push-to-release design), and the other to suit the turbo clutch (pull to release).Recommended transaxles are the 1975-on 091 four-speed range (bothBay-window and T25 versions) and the 094 five-speed range (T25 only)but, because Subaru engines rev high compared to VW engines (typically6500rpm minimum), the diesel T25 transaxles are generally unsuitabledue to their higher ratios.

OK, so what parts do I need?Based on a T25 conversion, you’ll need the Subaru engine, mountingrubbers (complete with nuts and washers to attach to the cross-member),flywheel – you’ll need to source one separately if the donor car isautomatic – clutch pressure plate and clutch release bearing (if from amanual donor and you want to re-use the clutch rather than fit a newone). You’ll also need the alternator, including the wiring with alternatorconnectors, clutch inspection hole cover, A/C compressor and pipes (ifrequired – not fitted to all Subarus, and not needed in most UK-specVWs) and the power-steering pump, fluid reservoir and pipes (if required),along with the power-steering pump bracket – even if the pump is not tobe supplied, as it’s needed for the alternator belt tensioner.

The list continues: all bell-housing-to-engine bolts – from the sameengine, the airflow meter and the induction pipe between the throttle bodyand the airflow meter itself. Then there’s the engine harness, lambda sensor,starter motor from a manual model, engine ECU, chassis harness frombehind the dash, transponder key immobiliser system (including thetransponder ECU), the ignition barrel sensor and the key module, if fitted toyour donor car. Note these latter parts MUST be from the same car as theECU, otherwise the engine won’t run – and the system can’t be removed.

Finally, you’ll also need the cluster of three relays on a steel bracketbehind the dash – one always has a green connector – and the electronicignition module (a small black box attached to the centre of the bulkhead,just above the gearbox), but note that this is not fitted to 1999-onwardsmodels, as the coils are fired directly from the ECU.

OK, so that’s what you need, in addition to the conversion kit itself.Take a look at the photos to see how we prepared the vehicle – a 19881.9DG-motored water-cooled Camper. Next month we’ll detail theinstallation itself. Stay tuned… ●

Contacts: www.rjes.com e-mail: info@rjes.com tel: 01538 752243

12. The ‘important’ bit of the conversion is the new RJES-designedcast-aluminium bell-housing (top right), which allows the Subaru

engine to be bolted up to the VW gearbox without an adaptor plate

14. While it’s empty, take the opportunity to clean up the engine bay.You’ll need to trim back the sheet metal at this point (arrowed) to

clear the coolant hoses, etc. Paint the edges to stop them rusting –

and keep your fingers away from those sharp corners!

13. Time for a sandwich and a cup of tea! We carried out theconversion in the open air on a rough tarmac driveway – you don’t

need exotic workshop facilities, although a power supply is useful

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